US5939015A - Centercore process for gas assisted injection molding - Google Patents
Centercore process for gas assisted injection molding Download PDFInfo
- Publication number
- US5939015A US5939015A US08/816,669 US81666997A US5939015A US 5939015 A US5939015 A US 5939015A US 81666997 A US81666997 A US 81666997A US 5939015 A US5939015 A US 5939015A
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- screw shaft
- gas
- injection molding
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- plastic
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0009—Making of catheters or other medical or surgical tubes
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M25/00—Catheters; Hollow probes
- A61M25/0009—Making of catheters or other medical or surgical tubes
- A61M25/0014—Connecting a tube to a hub
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1703—Introducing an auxiliary fluid into the mould
- B29C45/1732—Control circuits therefor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1703—Introducing an auxiliary fluid into the mould
- B29C45/1734—Nozzles therefor
- B29C45/1735—Nozzles for introducing the fluid through the mould gate, e.g. incorporated in the injection nozzle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/58—Details
- B29C45/60—Screws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/58—Details
- B29C45/62—Barrels or cylinders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/285—Feeding the extrusion material to the extruder
- B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
- B29C48/2886—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules of fibrous, filamentary or filling materials, e.g. thin fibrous reinforcements or fillers
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/505—Screws
- B29C48/51—Screws with internal flow passages, e.g. for molten material
- B29C48/515—Screws with internal flow passages, e.g. for molten material for auxiliary fluids, e.g. foaming agents
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/68—Barrels or cylinders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/50—Details of extruders
- B29C48/74—Bypassing means, i.e. part of the molten material being diverted into downstream stages of the extruder
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
- B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
- B29C48/83—Heating or cooling the cylinders
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
- B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
- B29C48/84—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders by heating or cooling the feeding screws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
- B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
- B29C48/84—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders by heating or cooling the feeding screws
- B29C48/845—Heating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
- B29C48/80—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders
- B29C48/84—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the plasticising zone, e.g. by heating cylinders by heating or cooling the feeding screws
- B29C48/85—Cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/88—Thermal treatment of the stream of extruded material, e.g. cooling
- B29C48/911—Cooling
- B29C48/9115—Cooling of hollow articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1703—Introducing an auxiliary fluid into the mould
- B29C45/1704—Introducing an auxiliary fluid into the mould the fluid being introduced into the interior of the injected material which is still in a molten state, e.g. for producing hollow articles
- B29C45/1706—Introducing an auxiliary fluid into the mould the fluid being introduced into the interior of the injected material which is still in a molten state, e.g. for producing hollow articles using particular fluids or fluid generating substances
- B29C2045/1707—Introducing an auxiliary fluid into the mould the fluid being introduced into the interior of the injected material which is still in a molten state, e.g. for producing hollow articles using particular fluids or fluid generating substances using a liquid, e.g. water
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/1703—Introducing an auxiliary fluid into the mould
- B29C45/1704—Introducing an auxiliary fluid into the mould the fluid being introduced into the interior of the injected material which is still in a molten state, e.g. for producing hollow articles
- B29C2045/1722—Introducing an auxiliary fluid into the mould the fluid being introduced into the interior of the injected material which is still in a molten state, e.g. for producing hollow articles injecting fluids containing plastic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/29—Feeding the extrusion material to the extruder in liquid form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- B29C48/295—Feeding the extrusion material to the extruder in gaseous form
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
Definitions
- This invention relates to the simultaneous or sequential introduction of multiphase matter into a plastic melt through a plasticating screw.
- plastic in molds or dies have been treated by introduction of matter through the wall of the mold, for cooling or the like, or matter has been added only to the plastic as it is worked between the plasticating screw and the housing in which it is rotatively supported.
- the present invention discloses a novel way to introduce high pressure gas, vapors and/or liquids into the process of manufacturing plastic material by a plasticating screw machine.
- the invention comprises drilling (coring) a hole axially through a plasticating screw of appropriate size to accommodate the introduction of gas, vapors and/or liquids into the melt shot.
- a non return shut off valve may be arranged on the tip of that plasticating screw, which valve is made with a drilled hole through it including the tip so that during or after the injection phase (short shot) or in the process of completion the tip opens either due to air pressure, mechanical actuation (spring loaded) etc. to allow the assist gas, vapors or liquids to hollow out the plastic part, where that screw is utilized in an injection molding operation.
- a finely controlled gas (typically nitrogen) pressure and volume may be applied to the driving (proximal) end of the plasticating screw by means of a rotational collar. The gas will pass through the length of the screw to the non return shut off valve, or tip, where it will enter the molten plastic material.
- Required gas volume or material viscosity may necessitate fine gas entry apertures such as with a jewelled orifice and/or a gas check valve to prevent material from blocking gas passages.
- a typical processing sequence will be incorporated to the gas cycle. The part will be a short shot. The screw will remain fully forward through the second stage while gas is applied (no cushion). After this phase, allowances must be made for venting or degassing of the unnecessary gas before the part is ejected, when utilized in an injection molding format.
- the introduction of gas, vapors, or liquids into the plasticating screw is from the rear of the screw in one embodiment, or from a design mated entry point, such as a radial channel from a collar radially outwardly of the screw and into the core of the reciprocating injection screw in a further embodiment.
- Assist media is proportionally regulated via the described gas control system to allow for maximum efficiency of profiling.
- a description of the mechanical aspects of - the invention includes: (a) Injection screw coring for the introduction of gas, vapor, or liquids (fluids); (b) Non return shut off valve threaded onto the delivery end of the sculptureticating screw for the purpose of: (1) shuting off the backflow of the molten plastic during an injection, holding and cooling phase of the plastic, (2) Enhancing the mixing of the molten plastic, (3) Allowing for the passage of high pressure gas, vapors or liquids through the center hole drilled (to specific size) through the center of the injection screw tip (aka non return valve), (4) Prevent plastic coming into center core during the screw recovery or plastification phase.
- the center bore in the sculpturetication screw is arranged to accommodate the passage of gas, vapor, liquids through the screw injection tip under certain pressures and temperatures.
- the center core hole should also be able to accommodate single, double or multiphase coaxial tubes for the passage of multiphase materials with a conveying point in the injection tip. Temperature control is of paramount value for the constituent plastics being worked.
- a high pressure rotary union may be arranged at the back end of the screw depending as to whether constituents are introduced axially or radially.
- the phase process for injection molding plastics utilizing the center cored screw comprises: (a) Injection phase: control by a control circuit of the melt and high pressure gas, vapor, or liquid and temperature control thereof, (b) Holding and Cooling phase: control of gas, vapor, or liquid pressure and temperature for efficient cooling of the molded parts to control surface finish and part shrinkage.
- a PID (proportional integral derivative) controlled micro-controller comprises a further embodiment of this invention.
- This Proportional Controller is a closed loop PID controlled pressure regulating system, having a digital (LCD) display used as an attachment to commercially available gas control systems.
- LCD digital
- the proportional control is achieved through an electro-pneumatic circuit with a proportional regulator (or valve) pilot operating a booster unit which then pilot operates a high pressure regulator.
- Low pressure compressed air 0.55-0.70 MPa (typically 80-150 psi) is used as a control pressure which then regulates the pressurized gas to desired levels up to a maximum of 103 MPa ( ⁇ 15,000 psi max.).
- the proportional regulation is controlled by a Pulse Width Modulating (PWM) controller operating a normally closed on/off three way valve . Upon the completion of the cycle, the line pressure from the gas tubing can be vented through a vent port in the "dome” regulator.
- PWM Pulse Width Modulating
- a downstream high pressure transducer attached to the gas line provides feedback to the micro-controller thus adjusting the PWM proportional valve to the set point (closed loop).
- This closed loop system with a full PID control algorithm and controlled by the micro-controller allows the gas pressure to be controlled via a voltage (or current) profile thus creating an infinite number of pressure versus time settings.
- An on-board RS232 interface allows the capability to capture the information from the gas pressure transducer before the gas enters the mold and thus may be used as a monitoring and statistical tool.
- a PC displays a menu system, where pressure can be profiled either up or down as a geometric function.
- a digital display is arranged to show the pressure set point and the actual value (during cycle).
- the micro-controller PWM
- PWM micro-controller
- Ports for the pressure sensor, RS232, allow for data acquisition and valve control signals (#1, #3, #5, #6) allow voltage input into the controller board.
- the pressure settings are easily adjusted within a pressure sensitivity scale of ⁇ 1 psi and can be seen on screen as setpoint vs. actual. Adjustments to the software are made using diagnostics modeand coarse adjust.
- the response time of the PID controller from the start of the cycle to reaching the setpoint is approximately 50 milliseconds (response time can be adjusted to specific needs).
- a prototype of the micro-controller is currently used with the gas control system on for example, a 250 Ton 32 oz. Cincinnati Milacron injection molding machine as an added feature to study the process parameters of the gas-assisted injection molding process.
- a Gas-Assist Controller system will be attached to an existing commercial gas unit utilizing the volume controll technique and will be operational as an integrated attachment.
- the system has features for multiple independent channels (if needed), closed loop control, 0-5 VDC control signals, PID control algorithm, pulse width modulating (PWM) outputs, option for extra pressure transducers, input signal conditioning, RS232 monitor, and operator interface (Keyboard/LCD).
- PWM pulse width modulating
- Equipment operation for gas heating/cooling by this system would allow for pressurization of N 2 by the gas (N 2 ) itself or shop air (150 psi), whichever suits per need.
- N 2 is not used as a control mechanism, a Tee fitting and gas regulator would be eliminated from the overall system operation.
- a high pressure gas (up to 15,000 psi) may be used as both the control mechanism as well as the actual set pressure gas to hollow out the molten plastic.
- a proportional regulator is arranged to provide precise pressure control with a flow control valve loading a "Dome” loaded high pressure regulator to make the gas setpoint (set on the PID controller).
- a second Tee fitting may be used as a split for the gas injection stage and the gas packing/holding/cooling state.
- a first circuit would allow the actuation of a 2 way solenoid valve.
- a heat exchanger heating element of the system would heat the gas to a desired set temperature and fill the gas into the accumulator.
- both the pressure and the temperature would be measured by a pressure transducer and a temperature sensor.
- a solenoid valve is arranged in the system to open and allow the free passage of pressurized gas through a fixed jewel orifice and into the mold cavity.
- a pressure sensor and a temperature sensor may be placed before the jeweled orifice to measure the pressure and temperature just before the gas enter the mold.
- the solenoid valves are arranged to close.
- the N 2 would now be diverted to a second circuit where a humidifier device may add small amounts of H 2 O to the N 2 and the components would be cooled to a set temperature by a heat exchanger cooling element in the system.
- a 2 way solenoid valve is arranged to open, allowing the mixture to pass through the orifice with pressure sensor and temperature sensor recording the pressure and temperature of the cold mixture. This phase of the cycle would assist in making hollow injected molded parts.
- the invention includes: (1) a gas injection molding system comprising a screw for delivering plastic material to a mold and a gas injection jeweled orifice port through the screw tip for injecting gas, vapor, or liquids into the plastic in the mold; (2) a gas injection closed loop pressure control system using a dome regulator ratio device with a micro-processor based control system to profile (ramp/step) the gas injection using a menu driven system allowing various time/pressure durations in the gas injection phase and the gas holding/packing phase.
- This can be either a personal computer (PC), Programmable Logic controller (PLC) or an embedded system with either a Proportional Integral Derivative (PID) or FUZZY logic algorithm; and (3) a control system for controlling the temperature of the gas during the injection phase and cooling phase.
- PC personal computer
- PLC Programmable Logic controller
- PID Proportional Integral Derivative
- FUZZY logic algorithm FUZZY logic algorithm
- the invention further includes a control for the injection stage velocity of the gas.
- the temperature of the gas may be heated by a heater. This will increase the gas viscosity thus limiting or helping prevent "gas blow out” from the molded part during the process cycle. It will also add to the temperature uniformity which will decrease the tendency of the part to have sink marks due to the thermal differences between the melt, mold and gas.
- a number of gases can be used.
- One such effective way is to have a phase change in the part for doing the cooling.
- a mixture of cold air with water spray will convert the spray into ice crystals which are conveyed with the air and once they hit the inside of the plastic part the ice will convert the water vapor with a large latent heat of sublimation (about 1100 Btu/lb).
- the pressure will increase and a control device will allow the part to be vented via a pressure regulator after which the process of air/ice injection is repeated until the part is sufficiently cooled.
- a third method would be to use liquid nitrogen. The liquid would evaporate and extract heat from the inside of the part. Also, the nitrogen (N 2 ) could be recovered.
- the hydraulic injection cylinder is coupled to the screw shank for inject and retract functions.
- the screw shank may also pass through a gearbox which provides rotation during plasticizing.
- the flight includes feed, transition, and metering sections of the screw.
- the screw tip or valve will typically incorporate a check ring or ball.
- FIG. 1 is a side elevational view of a plasticating machine assembly, partly in section;
- FIG. 2 is a side elevational view of a plasticating screw with a valve shown arranged on its distal tip end;
- FIG. 3 is a longitudinal sectional view taken of a plasticating screw showing both radial entry and axial entry embodiments for delivery of gas into the axial center core for introduction into a plastic melt through the screw tip;
- FIG. 4 is an exploded view of a plasticating screw with a non-return valve on its distal end;
- FIG. 5 is a side elevational view of a non-return valve
- FIG. 6 is a schematic view of a ball check valve
- FIG. 7 is a side elevational view of a non-return valve and portions of a screw shaft therewith;
- FIG. 8 is a schematic representation of the control circuit for the present invention.
- FIGS. 9a and 9b represent schematic and panel layouts of the controller portion of the control circuit of the present invention.
- FIG. 10 is a block diagram for one channel of the controller of the present invention.
- FIG. 11 is a schematic diagram of gas supply components for the present invention.
- FIG. 12 is a schematic representation of the components for heating and cooling gas utilized with the present invention.
- FIG. 2 a sectional view of a reciprocating screw injection molding machine 10 arranged to introduce high pressure gas, vapors or liquids to assist injection molding of plastic material.
- This process is based on drilling (coring) a hole 12 axially through a reciprocating plasticating screw 14 as shown in FIG. 2, the hole 12 being of appropriate size to accommodate the introduction of gas, vapors or liquids into the melt shot.
- a non return shut off valve 16 as may be seen on the distal tip of the screw in FIG. 2, and shown also in FIG. 4, is shown more completely in FIGS.
- a finely controlled gas typically nitrogen
- the gas will pass through the length of the screw 24 to the non return shut off valve, or tip 26, where it will enter the molten material.
- required gas volume or material viscosity may necessitate fine gas entry apertures and/or gas check valving to prevent material from blocking gas passages.
- a typical processing sequence will be incorporated to the gas cycle. The part will be a short shot. The screw 24 will remain fully forward through the second stage while gas is applied (no cushion). After this phase, allowances must be made for venting or degassing of the unnecessary gas before the part is ejected.
- the introduction of gas, vapors, or liquids is from the rear (or design mated radial entry point to the core of the reciprocating injection screw, as described hereinbelow), and assist media is proportionally regulated via the described gas control system to allow for maximum efficiency of profiling.
- the injection screw hole should accommodate the passage of gas, vapor, liquids through the screw injection tip under certain pressures and temperatures.
- the center core hole 12 as shown for example in FIG. 2, should also be able to accommodate single, double or multiphase coaxial tubes 32, and 34, for the passage of multiphase materials with a conveying point in the injection tip. Temperature control is of paramount value for the constituent.
- a high pressure rotary union 36 is attached at the back (proximal) end of the screw 24, shown in FIGS. 3 and to the back of the screw 14, in FIG. 4, whether constituents are introduced axially or radially.
- a closed loop PID controlled pressure regulating system 40 is shown in schematic form, in FIG. 8, with a digital (LCD) display may be used as an attachment to a commercially available gas control systems.
- LCD digital
- the proportional control is achieved through an electro-pneumatic circuit with a proportional regulator (or valve) 41 pilot operating a booster unit through which the pilot operates a high pressure regulator 47.
- a low pressure compressed air 0.55-0.70 MPa (typically 80-150 psi) source 11 is used to control pressure which then regulates the pressurized gas to desired levels up to a maximum of 103 MPa ( ⁇ 15,000 psi max.).
- the proportional regulation is controlled by a Pulse Width Modulating (PWM) controller 42 operating the normally closed on/off three way valve 41.
- PWM Pulse Width Modulating
- a downstream high pressure transducer 46 attached to the gas line provides feedback to the micro-controller thus adjusting the PWM proportional valve to the set point (closed loop).
- This closed loop system with a full PID control algorithm and controlled by the micro-controller allows the gas pressure to be controlled via a voltage (or current) profile thus creating an infinite number of pressure versus time settings.
- An on-board RS232 interface unit 43 allows the capability to capture the information from the gas pressure transducer before the gas enters the mold 45 and thus be used as a monitoring and statistical tool.
- a PC may display a menu system, where pressure can be profiled either up or down as a geometric function.
- a digital display panel 50 shown in FIG. 9b shows the pressure set point and the actual value (during cycle).
- the micro-controller PWM
- PWM micro-controller
- Valve control signals 56 allow voltage input into the controller board.
- the pressure settings are easily adjusted within a pressure sensitivity scale of ⁇ 1 psi and can be seen on screen 68 as setpoint vs. actual. Adjustments to the software are made using diagnostics mode switch 69 and coarse adjust switch 71.
- the response time of the PID controller from the start of the cycle to reaching the setpoint is approximately 50 milliseconds (response time can be adjusted to specific needs).
- the logic diagram of the micro-controller is shown in FIG. 10.
- a prototype of the micro-controller is currently used with the gas control system for example, on a 250 Ton 32 oz. Cincinnati Milacron injection molding machine as an added feature to study the process parameters of the gas-assisted injection molding process.
- FIG. 11 is a schematic diagram of a gas supply system 76 for the present invention.
- the system 76 may be attached to an existing commercial gas unit utilizing the volume controlled technique and may be operational as an integrated attachment.
- the system 76 may be arranged to operate and allow for pressurization of N 2 by the gas (N 2 ) itself or shop air (150 psi), whichever suits the need.
- Tee fitting 81 and gas regulator 82 would be eliminated from the overall system operation.
- the high pressure gas up to 15,000 psi
- a proportional regulator would provide precise pressure control with a flow control valve loading a "Dome” loaded high pressure regulator 85 to make the gas setpoint (set on the PID controller).
- Another Tee fitting 86 would be used as a split for the gas injection stage, shown as the first circuit "A", in FIG. 12, and the gas packing/holding/cooling state, shown as the second circuit "B" in FIG. 12.
- circuit A would allow the actuation of a 2 way solenoid valve 87.
- a heat exchanger heating element 88 would heat the gas to a desired set temperature and fill the gas into the accumulator 89.
- both the pressure and the temperature would be measured by a pressure transducer 98 and a temperature sensor 99.
- a solenoid valve 90 would open and allow the free passage of pressurized gas through a fixed jewel orifice 101 and into the mold cavity 95.
- a pressure sensor 96 and a temperature sensor 97 would be placed before the jeweled orifice 101 to measure the pressure and temperature just before the gas enter the mold 95.
- the solenoid valves 90 and 87 Upon the completion of gas injection cycle, the solenoid valves 90 and 87 would close.
- the N 2 would now be diverted to circuit B where a humidifier device 92 would add small amounts of H 2 O to the N 2 and the components would be cooled to a set temperature by a heat exchanger cooling element 93.
- a 2 way solenoid valve would open 94 allowing the mixture to pass through the orifice 101 with pressure sensor 96 and temperature sensor 97 recording the pressure and temperature of the cold mixture. This phase of the cycle would assist in making hollow parts.
- the present invention includes a gas injection molding system comprising a screw for delivering plastic material to a mold. It also includes a gas injection jeweled orifice port through the screw tip for injecting gas, vapor, or liquids into the plastic being molded.
- the gas injection may use a menu driven system allowing various time/pressure durations in the gas injection phase and the gas holding/packing phase.
- This can be either a personal computer (PC), Programmable Logic controller (PLC) or an embedded system with either a Proportional Integral Derivative (PID) or FUZZY logic algorithm.
- the temperature of the gas may be controlled during the injection phase and cooling phase via the control system.
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Abstract
Description
Claims (9)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US08/816,669 US5939015A (en) | 1995-02-23 | 1997-03-13 | Centercore process for gas assisted injection molding |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US39320095A | 1995-02-23 | 1995-02-23 | |
US08/511,055 US5670112A (en) | 1995-02-23 | 1995-08-03 | Multiphase matter introduction with a plasticating screw arrangement |
US08/816,669 US5939015A (en) | 1995-02-23 | 1997-03-13 | Centercore process for gas assisted injection molding |
Related Parent Applications (1)
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US08/511,055 Division US5670112A (en) | 1995-02-23 | 1995-08-03 | Multiphase matter introduction with a plasticating screw arrangement |
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US5939015A true US5939015A (en) | 1999-08-17 |
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US08/511,055 Expired - Fee Related US5670112A (en) | 1995-02-23 | 1995-08-03 | Multiphase matter introduction with a plasticating screw arrangement |
US08/816,669 Expired - Fee Related US5939015A (en) | 1995-02-23 | 1997-03-13 | Centercore process for gas assisted injection molding |
Family Applications Before (1)
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US08/511,055 Expired - Fee Related US5670112A (en) | 1995-02-23 | 1995-08-03 | Multiphase matter introduction with a plasticating screw arrangement |
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Cited By (5)
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US20040185141A1 (en) * | 2003-03-21 | 2004-09-23 | Alfredo Li Preti | Self-cleaning mold valve with air injection system |
WO2004113048A2 (en) * | 2003-06-20 | 2004-12-29 | Cinpres Gas Injection Limited | Liquid assisted injection moulding method and apparatus |
CN100434255C (en) * | 2006-06-22 | 2008-11-19 | 上海交通大学 | Water-assisted extrusion molding method and device |
US9636082B2 (en) | 2001-08-24 | 2017-05-02 | The Cooper Companies Global Holdings Lp | Medical-surgical devices |
US10045756B2 (en) | 2003-03-29 | 2018-08-14 | The Cooper Companies Global Holdings Lp | Medical devices |
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US6403014B1 (en) | 1992-03-23 | 2002-06-11 | Incoe Corporation | Method for fluid compression of injection molded plastic material |
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US5670112A (en) * | 1995-02-23 | 1997-09-23 | Dynamic Mixer, Inc. | Multiphase matter introduction with a plasticating screw arrangement |
US5744092A (en) * | 1995-02-23 | 1998-04-28 | Halgren; Donald N. | Axially movable cluster conduits for plastic processing in a screw machine |
US6627134B2 (en) | 2000-09-05 | 2003-09-30 | Community Enterprises, Llc | Apparatus for molding multilayered articles |
AT410648B (en) * | 2000-10-13 | 2003-06-25 | Engel Austria Gmbh | DEVICE FOR INJECTION MOLDING OF PLASTIC |
US6958128B2 (en) * | 2003-11-21 | 2005-10-25 | Certainteed Corporation | Dynamic mixer screw tip |
US7320765B2 (en) * | 2004-04-30 | 2008-01-22 | International Automotive Components Group North America, Inc. | Gas pin for thermocouple for gas assisted injection molding |
US7182892B2 (en) * | 2004-04-30 | 2007-02-27 | Lear Corporation | Gas assisted injection molding with fixed volume gas reservoir and temperature control |
US7527493B1 (en) * | 2007-11-01 | 2009-05-05 | Md Plastics Incorporated | Precise control non-return valve |
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US5670112A (en) | 1997-09-23 |
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